U.S. patent application number 10/313387 was filed with the patent office on 2003-05-01 for pants type diaper and method for producing same.
This patent application is currently assigned to Curt G. Joa, Inc.. Invention is credited to Dahmer, Bradley M., McCabe, John A., Nehrlich, Richard J..
Application Number | 20030082340 10/313387 |
Document ID | / |
Family ID | 24141459 |
Filed Date | 2003-05-01 |
United States Patent
Application |
20030082340 |
Kind Code |
A1 |
McCabe, John A. ; et
al. |
May 1, 2003 |
Pants type diaper and method for producing same
Abstract
A pants-type diaper, is provided which is equipped with leg-hole
elastics which effectively encircle the leg-holes without
traversing the crotch region. Also provided are methods for
producing such diapers. Typical products of this type are provided
with an outer laminate, formed of an inner liner material and an
outer backsheet material between which the leg-hole elastics are
disposed. The invention provides for the removal of a strip of
inner liner material carrying undesirable crotch-region elastic
strands prior to lamination or combining of the remaining inner
liner with a complementary outer layer backsheet.
Inventors: |
McCabe, John A.; (Sheboygan
Falls, WI) ; Nehrlich, Richard J.; (Elkhart Lake,
WI) ; Dahmer, Bradley M.; (Sheboygan, WI) |
Correspondence
Address: |
RYAN KROMHOLZ & MANION, S.C.
Post Office Box 26618
MILWAUKEE
WI
53226-0618
US
|
Assignee: |
Curt G. Joa, Inc.
|
Family ID: |
24141459 |
Appl. No.: |
10/313387 |
Filed: |
December 6, 2002 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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10313387 |
Dec 6, 2002 |
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10085908 |
Feb 28, 2002 |
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6521320 |
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10085908 |
Feb 28, 2002 |
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09537157 |
Mar 29, 2000 |
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6482278 |
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Current U.S.
Class: |
428/137 ;
604/358 |
Current CPC
Class: |
Y10T 156/1015 20150115;
Y10T 428/24843 20150115; A61F 13/49017 20130101; A61F 13/15609
20130101; Y10T 156/1011 20150115; A61F 13/496 20130101; Y10T
156/1008 20150115; Y10T 156/1067 20150115; Y10T 428/24322 20150115;
Y10T 156/1084 20150115; Y10T 156/108 20150115 |
Class at
Publication: |
428/137 ;
604/358 |
International
Class: |
B32B 003/10; A61F
013/15 |
Claims
We claim:
1. A protective underwear arranged to be worn by a person having
legs to trap and collect loose or liquid waste products of the
person, said underwear comprising a pants-shaped chassis having a
front waist portion, a belly portion, a rear waist portion, a rear
back portion, a crotch portion, and a pair of leg openings disposed
on opposite sides of said chassis, with said crotch portion being
located between said leg openings and having a front section and a
rear section, said front waist portion and said rear waist portion
being joined together at the sides of said chassis, said belly
portion and said rear back portion being joined together at the
sides of said chassis, said underwear additionally comprising an
insert having an insert sheet and a liquid absorbent core disposed
between said insert sheet and said chassis, each of said leg
openings having a first arcuate section, a second arcuate section,
and an intermediate section, said first arcuate section having an
inner end located adjacent said core, said second arcuate section
having an inner end located adjacent said core, said intermediate
section being located adjacent said core between said inner ends of
said first and second arcuate sections, said front waist portion of
said chassis including plural transversely oriented elastic threads
extending parallel to one another, said plural transversely
oriented elastic threads encompassing a substantial portion of said
chassis from said waist portion into said belly portion to a point
adjacent said crotch portion, said underwear additionally
comprising at least two generally linear longitudinally oriented
elastic threads, with respective ones of said longitudinally
oriented elastic threads extending on opposite sides of said core
outside margins of said core and between said leg openings, said
longitudinally oriented elastic threads intersecting at least one
of said transversely oriented elastic threads of said belly portion
and intersecting at least one of said transversely oriented elastic
threads of said rear back portion to form an enclosed, rectangular
gasketed compartment for said liquid absorbent core closely
conforming to the perimeter of said core to prevent the egress of
liquid therefrom, said first arcuate section of each of said leg
openings being elasticized by at least one arcuate elastic thread,
said second arcuate section of each of said leg openings being
elasticized by at least one arcuate elastic thread, said at least
one elastic thread of said first arcuate section terminating at an
inner end, said at least one elastic thread of said second arcuate
section terminating at an inner end, said inner ends being spaced
from each other by a gap, said gap being located at said
intermediate section, and wherein a portion of one of said
longitudinally oriented elastic threads is located very close to
said gap in said intermediate section of one of said leg openings,
and a portion of the other of said longitudinally oriented elastic
threads is located very close to said gap in said intermediate
section of the other of said leg openings, whereupon said
longitudinally oriented elastic threads cooperate with said arcuate
elastic threads to elasticized said leg openings to enable said leg
openings to closely conform about the legs of the person.
2. The protective underwear of claim 1 wherein said compartment has
an area, wherein said insert sheet and said chassis are liquid
permeable, and wherein said underwear additionally comprises a
liquid impermeable layer disposed between said core and said
chassis and encompassing said area of said compartment.
3. The protective underwear of claim 1 wherein said underwear
additionally comprises a fluid acquisition layer located between
said insert sheet and said liquid absorbent core within said
compartment.
4. The protective underwear of claim 1 wherein said transversely
oriented elastic threads comprise two first groups and two second
groups, a first one of said two first groups being located in said
front waist portion and a second one of said first two groups being
located in said rear waist portion, a first one of said two second
groups being located in said belly portion and a second one of said
two second groups being located in said rear back portion, and
wherein said transversely oriented threads of said first groups are
spaced closer to one another than said transversely oriented
threads of said second groups.
5. The protective underwear of claim 1 wherein said underwear
includes a front section comprising said front waist portion and
said belly portion and a rear section comprising said rear waist
portion and said rear back portion and wherein portions of said
transversely extending threads that are located in either said
front section or said rear section of a distinctive color are
compared to said chassis to be readily visible by the person.
6. The protective underwear of claim 1 wherein said compartment has
a periphery and said insert sheet and said chassis are bonded about
said periphery of said compartment.
7. The protective underwear of claim 1 wherein said core is of a
generally rectangular shape.
8. The protective underwear of claim 1 wherein said chassis
comprises a backsheet and two inner sheets adhesively secured to
said backsheet, said inner sheets being of non-woven material.
9. The protective underwear of claim 1 wherein said transversely
oriented elastic threads and said longitudinally oriented linear
elastic threads sre of the same material.
10. The protective underwear of claim 9 wherein said arcuate
elastic threads are of a different material than said transversely
oriented elastic threads.
11. The protective underwear of claim 1 wherein said chassis
material is a polylaminate.
12. The protective underwear of claim 11 wherein said polylaminate
is polyfilm laminated to a non-woven material.
13. The protective underwear of claim 1 wherein said insert sheet
comprises a non-woven material.
14. The protective underwear of claim 13 wherein said non-woven
material is spunbond polypropylene.
15. The protective underwear of claim 13 where said non-woven
material is zone-coated spunbond polypropylene, having a
longitudinal central area that is hydrophilic and two longitudinal
side areas that are hydrophobic.
16. The protective underwear of claim 1 wherein said core is formed
of a highly moisture absorbent material.
17. The protective underwear of claim 16 wherein said core is
formed of pulp and a superabsorbent particulate.
18. The protective underwear of claim 16 wherein said core is
formed of an airlaid composite, containing pulp, superabsorbent
particulates and/or fibers, and at least one binder.
19. The protective underwear of claim 18 wherein said at least one
binder is selected from the group consisting of chemical and
thermal binders.
20. The protective underwear of claim 1 wherein said chassis
comprises a non-woven material.
21. The protective underwear of claim 20 wherein said non-woven
material is a spunbond polypropylene material.
22. The protective underwear of claim 20 wherein said non-woven
material is spunbond/meltblown/spunbond polypropylene.
23. The protective underwear of claim 22 wherein said insert sheet
is an apertured three dimensional film or a combination of such
film and a non-woven material.
24. The protective underwear of claim 23 wherein said compartment
has an area, and wherein said underwear additionally comprises a
liquid impermeable layer disposed between said core and said
chassis and encompassing said area of said compartment.
25. The protective underwear of claim 24 wherein said liquid
impermeable layer is microporous polyfilm, which is vapor
permeable.
26. The protective underwear of claim 24 wherein said liquid
impermeable layer is polyethylene film.
27. The protective underwear of claim 26 wherein said underwear
additionally comprises a fluid acquisition layer located between
said insert sheet and said core.
28. The protective underwear of claim 27 wherein said fluid
acquisition layer comprises a thru-air-bonded, bicomponent fiber
with a fast finish surfactant.
29. The protective underwear of claim 26 wherein said fluid
acquisition layer comprises an apertured three dimensional film or
a combination of such film and a non-woven material.
Description
RELATED APPLICATION
[0001] This application is a continuation of co-pending application
U.S. Ser. No. 10/085,908, filed Feb. 28, 2002, which is a
divisional of U.S. Ser. No. 09/537,157, filed Mar. 29, 2000, and
which is now U.S. Pat. No. 6,482,278.
BACKGROUND OF THE INVENTION
[0002] The invention relates to disposable garments, and more
particularly, a pants-type diaper, which is equipped with elastics
strips effectively encircling the leg-holes without traversing the
crotch region and to a method for producing such diapers.
[0003] Disposable diapers of the children's training pant type, or
of the adult incontinence type, are typically equipped with elastic
strands, which encircle the leg-holes. These strands of elastic are
typically captured with adhesive between two layers of non-woven
materials. Various methods are used to position these elastic
strands so that they produce the desired encircling effect.
[0004] In one method of manufacture, the diapers are produced in an
orientation whereby product flow is in the form of a single
continuous web and the direction of travel is at a right angle with
respect to what would be described as the crotch line of the
diaper, i.e., the normal direction of product flow is parallel to
the waist as opposed to parallel to the crotch.
[0005] One method of creating the desired effect of encircling the
leg holes of the pant with elastics is to interleave two swaths of
elastic strands, each curving across the face of the traveling web,
encircling about one half of the leg-hole areas and crossing the
path of the other. As a pair, they create a boundary around each
leg-hole cutout, which resembles a circle or ellipse. In practice,
however, the lateral excursions of the elastic lay-down device are
speed-limited. As the traveling web is moving at some speed in one
direction, and as the elastic lay-down device has speed and
acceleration limits in the cross-direction, there is a limit to the
steepness of the oblique angle which it is possible to form between
the two. The result of this limitation is usually seen in the form
of apparent incompleteness in the formation of the
leg-hole-encircling pattern, particularly at the crotch line, where
the two swaths cross each other.
[0006] From the point on the web at which one leg-hole pattern has
been completed to the point at which the next can be begun, the
elastic laydown device must reposition itself to a favorable
starting point. This period of repositioning occurs as the crotch
region passes the laydown device. As a result, the elastic strands
must also cross this region of the product, at which they may or
may not be attached by means of adhesives to the carrier webs.
Various means are used to control or limit the positional
relationships of the elastic strands in this region. The two sets
of strands may cross over each other, creating an "X" pattern, or,
they may loop back over to their respective sides, creating an "O"
at the center of the crotch region. Alternatively, they may be
mechanically stopped and prevented from crossing each other,
creating two sets of generally parallel lines at the crotch The
lay-down pattern used at the crotch will determine the final
appearance of the product in this area.
[0007] The shirring effect created by elastic strands when
laminated with any flexible fabric is well known. However, to have
this shirring effect applied to the crotch of a pant-type garment
can be undesirable. The elastics create a contractile force, which
tends to distort the garment at this location, thereby reducing the
garment's aesthetic appeal, effectiveness and comfort. Thus various
methods of reducing or eliminating the effects of the elastic
tension normally occurring at the crotch have been attempted. These
methods include the elimination of the adhesive bond between the
strands and the liner materials described in U.S. Pat. No.
5,745,922 as "unsecured space" as well as various methods of
cutting the strands to eliminate their effects.
[0008] While the presence of the leg-hole elastic strands at the
crotch region is claimed by some to be of benefit in biasing the
diaper's inner cuffs against the user's legs see U.S. Pat. No.
5,188,627; Igaue, et al, it is believed by the present applicants
that the disadvantages, described above, outweigh any
advantages.
[0009] As mentioned, one method of eliminating the undesired
effects of the elastic strands which cross the crotch region is to
sever them. This method is described in U.S. Pat. No. 5,660,657.
Unfortunately, such severing usually requires the introduction of a
transversely extending cut, which can result in a loss of web
tension in the severed part of the carrier web. This also creates
an undesirable opening in the diaper backsheet. A proposed solution
for this problem is taught in U.S. Pat. No. 5,707,470, wherein an
ultrasonic device is used to sever the elastic members, while the
carrier webs which encapsulate the elastics are left intact. See,
also, U.S. Pat. No. 5,643,396. Another problem associated with such
severing lies in the tendency of the unsecured severed ends of
elastic to retract to some point beyond the limits of any adhesive
pattern. Thus, the elastic strands are not controlled or anchored
near the ends of the adhesion pattern and may snap back to further
into the adhesive pattern. This results in an incomplete elastic
pattern and poor product characteristics.
[0010] One method of compensating for the incompleteness of the
encircling pattern entails insertion of an additional set of
elastic strips, running parallel to the crotch line and transverse
to the web path. See U.S. Pat. Nos. 5,634,917 and 5,660,657.
Typical products of this type are provided with an outer laminate,
which is formed of an inner liner material and an outer backsheet
material, between which the leg-hole elastics are disposed.
SUMMARY OF THE INVENTION
[0011] It is a principal object of this invention to provide an
improved method of producing pants type diapers and to provide the
resultant improved diapers. A pants-type diaper, is provided which
is equipped with leg-hole elastics which effectively encircle the
leg-holes without traversing the crotch region.
[0012] In accordance with one aspect of the invention, elastic
strands are eliminated from the crotch region of a pants type
diaper. In accordance with a related aspect, the invention provides
a method wherein undesirable elastic material is encapsulated and
then an interior longitudinal zone of material which contains the
undesirable elastic is cut away and removed. The invention provides
for the removal of a strip of inner liner material carrying the
undesirable crotch-region strands before the remaining inner liner
is combined or laminated with its complementary outer backsheet
layer.
[0013] In accordance with a further related aspect, the remaining
webs, which contain elastic strands, are subsequently laminated
with a cover sheet. In a preferred embodiment of the invention, the
remaining webs may be rejoined before lamination, thereby reducing
the segment of leg opening perimeter which is removed.
[0014] In one embodiment, the leg-hole elastic swaths are laid down
on an inner non-woven carrier web, following appropriate curving
patterns. The resultant composite web is then longitudinally slit
into two narrower webs. The inside edge of each narrower web is
then folded longitudinally to cover that part of the elastic
pattern which is to be removed. This operation serves to cover the
exposed adhesive and to entrap the elastics in this area. The
entrapped elastics and the material within which they are enclosed
are then removed by again slitting the edge of the webs and
scrapping the waste edges. The remaining webs, with their
semicircular elastic patterns intact may then be subsequently
brought back to positions of contiguity by guiding means. This
relocation brings the two semi-circles together to form more nearly
perfect elastic circles or ellipses. The two narrower webs are then
laminated with an outer carrier web, which entraps the remaining
elastic swaths, creating a final laminated outer backsheet for the
pant-type diaper. Subsequent processes insert an absorbent chassis
or pad, cut out the leg-hole, fold the web longitudinally, and seal
and cut the web into individual pants type diapers.
[0015] A second embodiment of the invention involves a similar
process, but differs, in that instead of folding the slit edge of
the web over to cover and entrap the elastics which are to be
removed, separate strips of web material are introduced for this
purpose. Such web strips may be obtained by slitting them from
either the outer or inner edges of two narrow webs.
[0016] A third embodiment, a variant of the second embodiment,
covers and entraps the elastics with a single, wider strip of
material. Such web may be an edge previously cut and removed from
the inner liner material or may be separate material provided for
this purpose.
[0017] A fourth embodiment may be similar to one of the first,
second or third embodiments, but differs in that the two narrow
webs are not brought together prior to lamination. Instead, the
gaps or missing segments between two semi-circles around the leg
openings are replaced by elastics provided in the edges of an
absorbent chassis or pad, which overlays the crotch area.
[0018] In a yet further embodiment of the invention the
intermediate narrow strip of material is eliminated. A single web,
or if desired, a pair of traveling webs are provided onto each of
which an adhesive pattern is applied. The elastic strips are laid
down on the adhesive in a serpentine pattern. The strips may be
firmly secured to the adhesive by pressing them into the adhesive,
for example, by using a pressure roll. A chilled slitting knife may
be used in order to minimize adhesive build-up or contamination on
the knives. Also, the adhesive can be applied in a pattern which
leaves a gap in a strip along which slitting takes place, order to
facilitate clean cutting of the composite web. After slitting and
removal of the trim, a back sheet is applied which results in the
elastic strips being sandwiched between the slit webs and the
backsheet.
[0019] Briefly, a preferred method of the invention includes the
steps of providing a web, defining on the web a portion of a pants
type diaper including locations for leg openings and a crotch area
there between. Then, a layer of adhesive is applied around the leg
openings and across the crotch area.
[0020] An elastic ribbon is laid down on the adhesive in a
semicircular pattern around the leg openings and across the crotch
area. Subsequently a narrow web is laid down over the elastic and
the adhesive in the crotch area. Then the web is longitudinally
slit to sever at least a portion of the narrow web and the unwanted
elastic in the crotch area. The removed materials are scrapped,
resulting in a pants-type diaper without elastic in the crotch
region.
[0021] A cover sheet is laminated over the remaining web, and, all
material is removed from the leg openings. An absorbent pad is
preferably attached over the crotch area. The absorbent pad may
optionally be provided with elastic strips adjacent opposite
lateral edges which serve to complete the encirclement of the leg
openings by elastic material.
[0022] The invention, thus, produces a disposable garment including
a front body portion, a back body portion and an intermediate
crotch portion with spaced left and right leg openings on opposite
sides of said crotch portion. The edges of the front and back body
portions are joined to form a waist portion, the leg openings each
having an upper periphery adjacent to the waist portion and a lower
periphery adjacent to the crotch portion. The garment, further,
includes a back sheet which forms an outer surface thereof, a top
sheet and an absorbent pad positioned in the crotch area. In
accordance with the invention, there are front left and right
elastic strands which extend, respectively, around a quadrant of
each of the leg openings from forward ends which terminate at a
forward part of the crotch portion and around the upper periphery
of each of the left and right leg openings to the side seam.
Similarly, rear left and right elastic strands extend,
respectively, around another quadrant of each of the leg openings
from rearward ends which terminate at a rearward part of the crotch
portion and extend around the upper periphery of each of the left
and right leg openings to the side seam. The strands are adhered to
the top sheet, and to first and second narrow webs sandwiched
between the top sheet and the back sheet. The first narrow web is
adhered to the forward ends of each of the left and right elastic
strands and the second narrow web is adhered to the rearward ends
of each of the left and right elastic strands.
[0023] In its most basic form, the invention provides a method of
forming pants type diapers which includes the steps of (a)
providing a traveling fabric web upon which is defined a portion of
a pants type diaper including locations thereon for leg openings
and a crotch area therebetween, (b) applying an adhesive pattern on
the web around the leg openings, (c) laying down strips of elastic
material on the adhesive in an undulating pattern around the leg
opening locations on the traveling web and across the crotch area,
(d) forming a pair of parallel longitudinal slits along the center
of the traveling web to sever the central portion of the web
thereby severing the elastic in the crotch area, (e) removing the
severed portion of the traveling web and the elastic, laminating a
cover sheet over the severed halves of the traveling web, (f)
cutting and removing all material from the leg openings, (g)
severing the web into individual diaper blanks, (h) folding the
blanks in half across the crotch area, and, (i) sealing the edges
of the blank together on each side thereof to form a pants-type
diaper.
[0024] Further objects and advantages of the invention will be
apparent from the following detailed description, the attached
claims and the drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0025] FIGS. 1a-1c, collectively, are a perspective view showing a
preferred embodiment of the invention in somewhat diagrammatic
fashion;
[0026] FIG. 2 is a diagrammatic view of the equipment and process
shown in FIGS. 1a-1c;
[0027] FIGS. 3a-3b are, collectively, a perspective view showing in
somewhat diagrammatic fashion an alternative embodiment of the
invention;
[0028] FIG. 4 is a diagrammatic view further illustrating the
process and equipment shown in FIGS. 3a-3b;
[0029] FIGS. 5a-5g are a series of fragmentary plan views showing
sections of the web as it passes through the process and apparatus
of FIGS. 1a-1c and 2;
[0030] FIG. 5h is a fragmentary plan view showing a step subsequent
to that depicted in FIG. 5g but viewed from the opposite side of
the web;
[0031] FIG. 6a is a fragmentary plan view showing a web section at
a point where it leaves combining role number 124 in FIG. 3a;
[0032] FIG. 6b is a fragmentary plan view viewed from the opposite
direction shown in FIG. 6a and showing a section of the web after
it leaves roller 46 depicted in FIG. 3b;
[0033] FIGS. 7a-7g are fragmentary top plan views showing yet
another embodiment of the invention;
[0034] FIG. 7h is a fragmentary top plan view taken from the
opposite of the web shown in FIGS. 7a-7g at a subsequent point in
the process;
[0035] FIG. 8 is a top plan view showing an unfolded diaper blank
produced in accordance with the invention with the leg openings
removed;
[0036] FIG. 9a is a perspective view of the diaper blank of FIG.
8;
[0037] FIG. 9b is a perspective view showing the diaper of FIGS. 8
and 9a after final assembly thereof;
[0038] FIG. 10 is a fragmentary enlarged perspective view showing
the leg opening and elastics of the diaper of FIG. 9b;
[0039] FIG. 11 is a fragmentary perspective view showing another
embodiment of the invention in somewhat diagrammatic fashion;
[0040] FIGS. 12a-12c are a series of fragmentary plan views showing
sections of webs as passing through the process and apparatus of
FIG. 11; and,
[0041] FIGS. 13a-13c are another series of fragmentary plan views
showing sections of webs as passing through the apparatus of FIG.
11 in accordance with a modified process.
DETAILED DESCRIPTION OF THE INVENTION
[0042] Referring first to FIGS. 1a, 1b and 1c, one of the preferred
embodiments of the process of this invention and related apparatus
are illustrated. The process utilizes two main carrier webs; a
non-woven web 11 which forms an inner liner web, while web 12 forms
an outwardly facing layer in the finished diaper. In this
embodiment, non-woven web 11 is slit, at slitter station 15, by
rotary knives 14 along three lines. One of these, line 16, is on
approximately the centerline of web 11 and two additional lines 17
and 18 are parallel to and spaced a short distance from centerline
16. (See FIG. 5a.) The effect is twofold, first, to separate web 11
into two halves, as also seen in FIG. 5b. One half, 19, will become
the inside of the front of the diaper 50 and the second half, 20,
will become the inside of the back of that garment. Second, two
separate, relatively narrow strips 22 and 24 are formed which are
subsequently used to cover and entrap portions of the leg-hole
elastics 25 and 26. Strips 22 and 24 are separated physically by an
angularly disposed spreader roll 23 and aligned laterally with
their downstream target positions on the inner edges of webs 19 and
20.
[0043] As shown in FIG. 5c, adhesive patterns 21 and 27 are applied
to the web halves 19 and 20 in the target areas for the leg hole
elastics 25 and 26. A spray gun assembly 29 of a type known in the
art is preferably used to apply adhesive patterns 21 and 27. Two
sets of leg-hole elastic strands 25 and 26 are introduced through
laydown guides 28 and 30, which reciprocate from side to side past
each other. Strands 25 and 26 are glued to the web sections 19 and
20, their laydown patterns following a serpentine path. Given the
absence of adhesive in the area separating web 19 from web 20, for
some portion of each successive diaper product, the strands 25 and
26 each track parallel to the inner slit edges of the web sections
19 and 20. Laydown guides 28 and 30, thus, apply the strands 25 and
26 which form leg-hole elastics as the web sections 19 and 20 are
carried along the face of a drum or roll 32. Those parts of the
elastic patterns which are near the inner slit edges of webs 19 and
20 are then covered by the introduction of an adhesive lamination
thereover of the strips 22 and 24 of non-woven web also against the
drum 32.
[0044] The side-to-side excursions of the leg-hole elastic laydown
guides 28 and 30 result in arcuate segments of elastic strands
extending on each side of the web centerline as seen in FIGS. 5d
and 5e. After the non-woven strips 22 and 24 have been applied to
cover and entrap those parts of the elastics 25 and 26 which run
nearest to and parallel to the inner edges of the webs 19 and 20, a
second pair of slitter knives 34 (FIG. 2) are used to trim away a
portion of the narrow non-woven strips 22, 24, along with that part
of the inner liner webs 19, 20 to which they are laminated. This
also removes those portions of the elastic strands 25, 26 which are
contained within the laminations. The resultant trimmed scrap
strips 36 are removed from the process for disposal elsewhere.
[0045] The effect of the last-described step is to totally remove
the cut away portions of the elastic, eliminating its corresponding
unwanted gathering effect from the crotch region of the garments
50. The remaining portions of the curved elastic strands create a
gathering effect around the leg openings of the finished garments
50.
[0046] Subsequent to the combining and trimming of the inner webs
19, 20 and the cover strips 22, 24, the combining drum 32 carries
the webs to a point of approximate tangency with a second combining
drum 38, where the web sections 19, 20, with their respective
curved elastic patterns 21 and 27 exposed, are transferred to and
laminated adhesively against the inside face of outer liner web 12.
This process entraps the curved elastic patterns 25, 26 between the
inner and outer chassis webs 19, 20 and web 12 thereby forming a
composite web 39.
[0047] A succession of absorbent pads 40 are picked up at a supply
station 41 by vacuum heads 44 of a pad supplying/turning device 42.
The absorbent pads 40 are comprised of various absorbent materials
contained within a non-woven cover stock which are well known in
the art. The pads are rotated 90.degree. and applied, successively,
to the crotch areas of the composite web 39 by a transfer roll 46
where they are attached adhesively to the inside of the web 39
which forms the garment chassis. FIG. 5h shows a pad 40 attached to
the composite web 39. It should be noted that in FIG. 5h the web 39
is being viewed from the opposite side from that which is shown in
FIGS. 5a through 5g.
[0048] Leg hole materials 48, if not previously removed, are cut at
a cutting station 47, thereby removing the material 48 contained
within an approximate perimeter defined by the curved pattern of
the elastics 25, 26. The running composite chassis web 39 is
folded, before or after cutting out of the leg holes,
longitudinally along its centerline, thereby aligning its front
waist edge 51 with its back waist edge 52. The regions 53 which are
to become the side seams 54 of the garments 50 are then welded by a
sealing device 49 either ultrasonically or by heat. Note that the
leg-holes are preferably cut out before this point, leaving only a
narrow zone for welding. The weld pattern is preferably wide enough
to extend into both the left side seam of one garment and the right
side seam of the adjacent garment. The garments 50 are then
separated by passing through a cut-off knife assembly 55, which
severs the web along the transverse axis of the side seam weld
53.
[0049] Referring to FIG. 3, there is shown an alternate embodiment
of the invention which provides a process that results in bringing
of the front and back leg hole elastics into closer proximity with
each other. In the embodiment shown in FIGS. 3a and 3b, this is
accomplished by beginning with a web of material 111 and slitting
the same, for example, by means of a rotary knife 114 into two
halves, 119 and 120. It will be appreciated that instead of cutting
the web 111 into halves that the process could also be practiced by
providing the narrower webs 119 and 120 from two separate sources
of material. As shown, the two webs 119 and 120 are brought into
the process utilizing two separate combining drums, 121 and 122,
each of which lays down its respective web 119 and 120 onto a
larger rotating drum 124. In the illustrated embodiment a narrow
strip 126 is removed by means of a rotary knife 125 from web 119.
Similarly a rotary knife 128 removes a strip 129 from web 120. As
shown in FIG. 3a, elastic strands 130 are applied in an oscillating
pattern onto web 119 at combining drum 121 and the inwardly facing
edges thereof are covered by the narrow web 126. Similarly an
elastic 132 is applied to web 120 immediately prior to covering of
the inwardly facing edge thereof by means of narrow web 129.
Adhesive patterns are applied by applicators 134 and 136,
respectively, to form spray patterns 140 and 138 which are shown in
FIGS. 6a and 6b. After the elastic 130 has been laid upon web 119
on combining drum 121, the inwardly facing edge thereof is cut by
means of a rotary cutter 142, thereby removing a strip of scrap
material 144 which includes the inner edges of web 119 and narrow
strip 126 together with that portion of elastic 130 which is
sandwiched therebetween. The identical process takes place on
combining drum 122 with respect to web half 120 where, after
lamination of elastic 132 between the inner edge of web 120 and
narrow strip 129, a rotary knife 146 removes the severed portion of
the webs and elastic 148. The resultant laminated webs 119 and 120
are then applied to a backsheet web 150 on combining drum 124. This
results in a combined web 152, also illustrated in FIG. 6a.
[0050] Then, as in the case of the earlier described embodiment, a
pad turning and supplying assembly 42 utilizing vacuum heads 40
supplies a series of absorbent pads 153 to a transfer roll 46 which
applies each pad successively in each crotch area on the combined
web 152. As best seen in FIG. 6b, the absorbent pads 153 may be
supported on a sheet of absorbent web material 154 which is bonded
to the composite web 152 by means of ultrasonic welding, heat, or,
if desired, by means of adhesives. As best seen in FIG. 6a the
bringing of the webs 119 and 120 into close proximity to each other
makes it possible for the elastics 130 and 132 to effectively
encircle the leg areas with only an insignificant gap between them.
This reduces or eliminates the need for introducing elastics along
the lateral edges of the pads 153.
[0051] The embodiment of FIGS. 3a and 3b is shown in diagrammatic
form in FIG. 4. FIG. 4 also illustrates the steps of folding the
composite web in half at a folding station 156, cutting out the leg
hole material 159 and a cutting station 158. Then, side seams 161
are formed at a sealing station 160. The side seams 161 are severed
along their approximate center line at another cutting station 162.
This results in the finished diaper garment 164 which have side
seams 161 on each side of the garment.
[0052] Referring to FIGS. 8-10, there is seen, in FIGS. 8 and 9a, a
blank for a diaper garment 50 which may be produced by the
apparatus and method shown in FIGS. 1-1c or, alternatively, by that
shown in FIGS. 7a-7h. In this embodiment the leg openings have been
cut out leaving the strands 25 and 26 partially encircling the leg
openings. A pad 40 supported on a web 60, which may also be formed
of non-woven absorbent material, has been applied to the crotch
area. A separate strand of elastic material 62 and 64 positioned on
opposite sides of the pad 40 provides a means to complete the
approximate encirclement of the leg openings by means of elastic
material which, as in the earlier described embodiment, is somewhat
discontinuous. Thus, the ends of elastic strands 25 and 26 which
are inwardly terminating in the crotch area are secured by the
narrow webs 22 and 24 as seen in FIGS. 9a and 9b, as well as in
FIG. 10. The elastic strands 62 and 64 are thus spaced away from
the ends of elastics 25 and 26. This arrangement provides for a
comfortable fit around the legs of a wearer but without any
bunching tendency in the crotch area which might cause
discomfort.
[0053] Also, as seen in FIGS. 9-10 waist elastics 66 are provided
on opposite sides of the garment blank which, after folding
together and formation of the side seams 54, entirely encircle the
waist area of the finished garment 50. Note, also, in FIGS. 9b and
10 that the ends of the elastics 25 and 26 which extend furthest
away from the crotch area also become secured by means of the side
seams 54.
[0054] Referring next to FIGS. 7a-7h, there is illustrated a
sequence of steps illustrating yet another embodiment of the
invention. In accordance with the embodiment of 7a-7h, a web 211,
as depicted in FIG. 7a, is slit into two halves 219 and 220 as it
travels through the process. Then, adhesive patterns 221 and 227
are applied, as shown in FIG. 7c, to the respective web halves 219
and 220. Elastic strips 225 and 226 are then applied in an
undulating pattern, as shown in FIG. 7d. Then, the inner edges of
the webs 219 and 220 are folded over on themselves thereby covering
and securing the portions of elastic strips 225 and 226 which are
nearest the cut line 218 between webs 219 and 220. As also seen,
the portions of elastic strands 225 and 226 which traverse the
crotch region of the diaper being manufactured are captured along
the fold line between folded over strip 222 and the remainder of
web 219 and similarly along the fold line between the folded over
portion 224 and the remainder of web 220.
[0055] Referring to FIG. 7f, the two web halves 219 and 220 are
seen after severance therefrom of the inner edges or folds of the
folded over flap portions 222 and 224. Thus, it will be appreciated
that the ends of elastic strands 225 and 226 nearest the crotch
region of the diaper are anchored in place by the remaining width
of the strips 222 and 224 and the webs 219 and 220,
respectively.
[0056] In FIG. 7g a cover sheet 212 has been laminated over the web
halves 219 and 220. The adhesive areas 221 and 227 which flow into
the webs 219 and 220 are not shown in this view, since they are no
longer discrete entities. The elastic strands 225 and 226 have been
at this point sandwiched between the layers 212 and 219 or 220,
respectively with the ends thereof firmly anchored by the narrow
strips 222 and 224 which are also sandwiched between the covering
web 212 and the original web halves 219 and 220.
[0057] Referring to FIG. 7h, the assembled diaper forming materials
of FIG. 7g are shown from the opposite side of the web and with an
absorbent pad 240 secured thereto. As in the earlier embodiments,
pad 240 is attached to a supporting web 260. Also, in this case
elastic strands 262 and 264 are attached to the carrier web 260 so
that the gaps between the ends of each of the elastics 225 and 226
which lie closest to the diaper crotch area are provided with an
elastic material. Note, again, that the strands 262 and 264 are
displaced slightly from the ends of the strands 225 and 226 which
are anchored by the narrow strips 222 and 224. It will, thus, be
appreciated that after the removal of the leg opening materials
from the combined webs of FIG. 7h, a blank is provided which is
virtually identical to that shown in FIGS. 8 and 9a. Accordingly,
the resultant diaper is also virtually identical to that
illustrated in FIGS. 9b and 10.
[0058] Referring to FIG. 11, there is seen a modified process of
this invention wherein the narrow covering strips 22 and 24, shown
in connection with the earlier described embodiments, are not used.
Instead, diapers and diaper blanks are produced wherein elastic
strands 25 and 26 become sandwiched between a fabric web 311 and a
back sheet 12. In FIG. 11 the apparatus and components having the
same numbers used in connection the earlier described embodiments
refer to the same components.
[0059] As seen in FIG. 11, a non-woven web 311 is cut along its
center line, longitudinally, by means of a rotary knife 14 along a
central cut line 318, thus forming two narrower web halves 319 and
320. A sequence of the processing steps relating to the web halves
319 and 320 are illustrated in part in FIGS. 12a-12c, steps which
are omitted being similar to those shown in connection with the
earlier-described embodiments. As in the case of the earlier
embodiments, adhesive patterns 320 and 321 are applied to the web
halves 319 and 320 by means of an adhesive applicator 29. Then,
elastic strands 25 and 26 are laid down by means of reciprocating
feeding devices 328 and 330, resulting in a pattern such as
illustrated in FIG. 12b. Note that intended trim lines 340 and 342
are shown for illustrative purposes in FIGS. 12a and 12b by means
of phantom lines. Note also from these figures that the adhesive
patterns 321 and 327 are omitted from strips over the cut lines 340
and 342. This procedure facilitates slitting of the webs 319 and
320 along the trim lines 340 and 342, respectively. The slitting
knives, thus, serve to cut the webs along these lines 340 and 342
without undo accumulation of adhesive on the knives.
[0060] The web halves 319 and 320 are shown subsequent to slitting
and removal of the elastic strips 25 and 26 from the crotch area in
FIG. 12c. It will then be appreciated that when an outside covering
web 12 is applied over the parallel traveling web halves 319 and
320 that the elastic strands 325 and 326 will be sandwiched between
the webs 12 and 319 or 320 and thus firmly held in place. Only a
small, inconsequential end of each of the strands 25 or 26 adjacent
to the slit lines 340 and 342 is left unanchored by the
adhesives.
[0061] Referring to FIGS. 13a-13c in conjunction with FIG. 11, a
further embodiment of the invention will be described. In this
variation the web 311 is not slit by a rotary knife prior to
application of the adhesive patterns thereto. Thus, the rotary
knife 14 of FIG. 11 can be omitted. As seen in FIG. 13a, the web
311 is intact when the adhesive patterns 421 and 427 are applied.
In other respects, these adhesive patterns are similar to those
illustrated in FIGS. 12a-12c. As in that case, the trim lines 440
and 442 are again shown by means of phantom lines. Also, again, the
adhesive patterns 421 and 427 can be configured so that adhesive is
omitted from strips along the intended trim lines. After
application of elastic strands 25 and 26 over the adhesive patterns
421 and 427, the web 311 is slit along the two parallel lines 440
and 442 resulting in two web segments 419 and 420, as seen in FIG.
13c. As noted by a comparison of FIGS. 12c and 13c, both of these
procedures result in virtually identical diaper blanks.
Subsequently, the leg hole areas are removed as in the case of the
earlier embodiments and waistband elastics can be applied at a
convenient point in the process. Then, the blanks are formed into
finished diapers, just as in the case of the earlier described
embodiments.
[0062] While various preferred embodiments of the invention have
been shown for purposes of illustration, it will be apparent to
those skilled in the art that various additional modifications can
be made falling within the scope of the invention as defined by the
appended claims.
* * * * *